Bulk inventory network system

ABSTRACT

A system and method for remote monitoring of material storage levels for dry bulk goods, wherein an independent entity, such as a transportation carrier, can continuously monitor raw material supply levels at a remote manufacturing plant, and, based on projected usage rates, place timely orders on behalf of the plant, with preselected vendors, to replenish depleted raw materials. The transportation carrier can then coordinate material shipments from the vendor to the manufacturing site using its own trucks. In this manner, the task of maintaining sufficient on site raw material storage levels is completely removed form the manufacturing plant.

This is a continuation of copending U.S. patent application Ser. No.11/003,253, titled BULK INVENTORY NETWORK SYSTEM, filed Dec. 3, 2004,which is itself a divisional application of copending U.S. applicationSer. No. 10/085,396, filed on Feb. 28, 2002, which is itself acontinuation-in-part application of U.S. application Ser. No.09/167,379, filed on Oct. 6, 1998, and issued as U.S. Pat. No.6,366,829.

FIELD OF THE INVENTION

The invention relates to the field of automated inventory management,and in particular concerns a system for remote monitoring of materialstorage levels for dry bulk goods, wherein an independent entity, suchas a transportation carrier, can continuously monitor raw materialsupply levels at a remote manufacturing plant, and, based on projectedusage rates, place timely orders on behalf of the plant, withpreselected vendors, to replenish depleted raw materials. Thetransportation carrier can then coordinate material shipments from thevendor to the manufacturing site using its own trucks. In this manner,the task of maintaining sufficient on site raw material storage levelsis completely removed from the manufacturing plant.

BACKGROUND OF THE INVENTION

Manufacturers frequently employ independent transportation carriers todeliver raw materials from vendor cites to manufacturing sites on anas-needed basis. Traditionally, manufacturers themselves monitor on-siteinventory levels and product usage rates, and, when material suppliesbecome low, a phone call is placed from the plant site to an outsidevendor to order another shipment of raw materials. Typically, atransportation carrier is separately contracted with to pick up the rawmaterial order from the vendor site and deliver the shipment to themanufacturer.

Raw material inventories must be continuously monitored and raw materialorders and shipments must be carefully coordinated to ensure asufficient amount of materials are always at hand. If material suppliesare exhausted before new material shipments can be delivered,manufacturers may be forced to temporarily shut down manufacturingoperations, resulting in lost production time and revenues.

When several raw materials are simultaneously used in productmanufacturing, the task of monitoring material levels becomesincreasingly difficult. An additional challenge is presented when theusage rate for each of these materials fluctuates over time.

In the case of dry bulk goods such as lime, coal and ash, for example,specially adapted trucks and trailers are often required fortransporting the materials from a vendor to a plant site. In order toensure the availability of a transport carrier when a material shipmentis needed, it is desirable to schedule shipments as far in advance aspossible. Thus, the ability to monitor existing material levels as wellas to project future material requirements is critical. Likewise, theability to quickly convey this information to a transport carrier isessential.

Several automated systems have been designed to facilitate themanagement of material inventories. For example, U.S. Pat. No.5,727,164—Kaye et al. discloses an inventory management system wherein acentralized inventory database can be remotely accessed to retrieveinformation.

U.S. Pat. No. 5,761,362—Cowe et al. discloses an inventory monitoringsystem wherein electronic shelf units automatically monitor productinventory levels.

U.S. Pat. No. 5,983,198, issued to Mowery, et al., provides a system andmethod for using a fleet of vehicles to provide material to a pluralityof tanks at various customer locations. An inventory indicatorassociated with each of the tanks provides a quantity signal to thecentral station indicating the quantity and temperature of each of thetanks. A processor at the central station monitors the quantity signalsof each of the tanks to determine past usage rates of the contents ofeach of the tanks. The processor projects future tank quantities basedon the past usage pattern and determines possible routes for each of thevehicles to each of the tanks. The processor optimizes the routes,delivery amounts, and delivery schedule to minimize total delivered costfor the products based on the projected future tank levels and thepossible routes to dispatch each of the vehicles. Each of the foregoingsystems allow some form of remote access to a centralized database tomonitor inventory levels.

While these systems enable material stores to be remotely monitored,they are not useful for monitoring dry bulk goods nor do they providemeans to interpret usage trends or project usage rates based on archiveddata.

What is needed is an automated system capable of continuously monitoringmaterial levels for dry bulk goods as well as projecting future usagerates for materials based on archived data. Preferably, the system wouldprovide for the automated transmittal of data to a remote site atpredetermined time intervals.

SUMMARY OF THE INVENTION

In one aspect of the invention a remote material monitoring system isprovided which can be used to monitor inventory quantities for rawmaterials at a remote site and automatically transmit signalscorresponding to existing material levels from the remote site to acentral computer at predetermined time intervals.

In another aspect of the invention a remote material monitoring systemis provided which includes a central computer having software meanscapable of determining material levels and projecting material usagerates based on signals transmitted from a remote material storage site.

In another aspect of the invention a remote materials monitoring systemis provided in which the central computer includes software means fordisplaying the material levels and projected usage levels in tablatureand graphical form.

In yet another aspect of the invention the central computer includessoftware means for sounding visual and/or audible alarms if the materiallevels being monitored fall below predetermined levels.

In yet another aspect of the invention a method is provided forcontinuously monitoring material levels in a storage vessel at a remotesite without human intervention.

In another aspect of the invention a method is provided for atransportation carrier to maintain sufficient raw material quantities ata remote manufacturing plant site.

These and other aspects are provided in a system for monitoring amaterial quantity at a remote manufacturing site. The system comprises adetector for producing a first output signal corresponding to anexisting material quantity. A remote telemetry unit receives the firstoutput signal from the detector and produces a corresponding secondoutput signal. A central computer is coupled to the remote telemetryunit for receiving the second output signal which is automaticallytransmitted to a central computer at predetermined time intervals. Thecentral computer includes software means for determining the quantity ofsaid existing material at the remote site as well as projected usagerates for said existing material based on the transmitted signals.

In a preferred embodiment of the invention the detector comprises anultrasonic or strain gauge detector and the remote unit and centralcomputer are coupled via modem for transferring the output signals fromthe remote unit to a central computer.

In another preferred embodiment of the invention, a system formonitoring a material quantity at a remote site is provided including asensor that produces a first output signal corresponding to a materialquantity within a storage vessel such as a dry bulk silo. A datacollector receives the first output signal from the sensor and producesa second output signal that is representative of the quantity ofmaterial remaining within the storage vessel. A remote telemetry unitreceives the second output signal and transmits a signal indicatingmaterial quantity to a central computer disposed in data communicationwith the remote telemetry unit.

In a further embodiment of the invention, a system for monitoringmaterial levels in storage vessels at a remote site is providedincluding a level detector that produces a first output signalcorresponding to a material level in one of the storage vessels. Thelevel detector may be selected from one of ultrasonic and strain gaugelevel detectors. A first computer receives the first output signal fromthe level detector and produces at least one second output signal thatis representative of the material quantity. A remote telemetry unit isarranged in data communication with the first computer so as to receivethe first output signal from the first computer and transmit an outputsignal to a second computer in communication with the remote telemetryunit. In some cases, the first computer may include means fortransmitting an output signal that is representative of the materiallevel directly to the second computer.

In yet a further embodiment of the invention, a system for monitoring amaterial level in a storage vessel at a remote site is providedincluding a level detector for producing an output signal correspondingto the material level, where the level detector comprises means fortransmitting the output signal to a remote telemetry unit that, in turn,transmits a signal indicating material quantity to a central computerdisposed in data communication with the remote telemetry unit. In someinstances, the level detector comprises means for transmitting an outputsignal that is representative of the level or quantity of material in astorage vessel to a central computer disposed in data communication withthe level detector for receiving the signal indicating materialquantity.

Also provided is a system for a transportation carrier to maintain asufficient quantity of raw material at a remote site. The system of thisembodiment includes a sensor that produces a first output signalcorresponding to a quantity of material located within a storage vessel,e.g., a dry bulk material silo. A data collector receives the firstoutput signal from the sensor and produces a second output signal thatis representative of the material quantity within the storage vessel. Aremote telemetry unit that receives the second output signal andtransmits a signal indicating material quantity data. A central computeris disposed in data communication with the remote telemetry unit forreceiving the signal indicating material quantity. The central computerincludes means for storing the material quantity data and for projectinga usage rate for the material based on the second output signal.

In addition, a method for a transportation carrier to maintainsufficient quantities of raw materials at a remote manufacturing site isprovided that includes the generation of a first signal representativeof an existing raw material quantity at a remote site. Transmitting asecond signal corresponding to the first signal from the remote site toat least one of a local computer and a central computer at predeterminedtime intervals. The existing raw material quantity and a projectedmaterial usage rate for the existing raw material quantity based on thetransmitted signals are determined. based upon this determination,additional raw materials are ordered from a preselected vendor based onthe existing material quantity and the projected material usage rate. Atransport vehicle is provided to deliver the additional raw materialfrom the preselected vendor to the manufacturing site by transportingthe additional raw material from the preselected vendor to themanufacturing site.

While the described system and method for monitoring and maintainingremote material stores are applicable for any bulk commodities, they areparticularly advantageous for use in connection with the storage of drybulk goods in storage silos or similar structures.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bemore fully disclosed in, or rendered obvious by, the following detaileddescription of the preferred embodiments of the invention, which are tobe considered together with the accompanying drawings wherein likenumbers refer to like parts and further wherein:

FIG. 1 is a block diagram of a remote inventory monitoring systemaccording to the invention;

FIG. 2 is a front elevational view of a typical storage vessel,including level detectors, and of the type used in connection with thepresent invention; and

FIGS. 3-8 are partially schematic block diagrams of alternativeembodiments of a remote inventory monitoring system according to theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This description of preferred embodiments is intended to be read inconnection with the accompanying drawings, which are to be consideredpart of the entire written description of this invention. The drawingfigures are presented in somewhat schematic form in the interest ofclarity and conciseness. In the claims, means-plus-function clauses areintended to cover the structures described, suggested, or renderedobvious by the written description or drawings for performing therecited function, including not only structural equivalents but alsoequivalent structures.

The invention concerns a Bulk Inventory Network System (BINS) used tomonitor customer inventories and order delivery of dry bulk materials.In one preferred embodiment, the BINS system depends upon transmissionof data from remote customer sites to a centrally located computer.Information, transferred by telephone communications, consists of thelevel or weight of material in storage at the customer's business. Whena trigger level or minimum volume of material is reached, dispatchersare notified that a shipment of dry bulk materials should be deliveredto the customer's site. Customer storage records are also monitored bythe BINS central computer, displayed on a trend graph, and stored as ahistorical record of dry bulk material usage by the customer.

Referring to FIG. 1, a remote inventory monitoring system 10 accordingto the invention comprises a central computer 12 and a first modem 14,which are distant from the dry bulk material storage vessel 15 beingmonitored. One or more remote telemetry units (RTU,) 16, a second modem18 and a level detector 20 are disposed at the storage vessel site.Typically, level detector 20 is positioned directly on storage vessel15. Software means are installed and continuously running on centralcomputer 12. The software means receive and store data transmitted fromRTUs 16 at each storage vessel 15 in remote inventory monitoring system10. The software means also determine existing material levels andquantities 22, as well as projected usage rates for each material basedon the transmitted data. In addition, the software means are programmedto activate a visual and/or audible alarm (i.e., flashing icon and/orbeep) as well as to display the information on a trend graph for easyviewing.

Two alternative means are used to control and operate remote inventorymonitoring system 10. A first preferred means is used in connection witha remotely controlled system. The remotely controlled system utilizes amicroprocessor based RTU 16 that is programmed to receive a first outputsignal from level detector 20, produce a second output signalcorresponding to said first output signal, place a telephone call tocentral computer 12 and transfer data to the computer. In this system,each RTU 16 controls data collection and transmission, and therefore,requires relatively sophisticated programming. RTUs 16 are oftenconfigured using a laptop computer connected directly to a port in theRTU at the storage site. Under the remote control concept, centralcomputer 12 acts primarily as a data storage and display device:Standard personal computers may be utilized for this portion of thesystem.

Changes to system operations, such as time intervals between datatransmissions, usually require a trip to storage vessel 15 site formodification of the RTU programming.

In a second preferred embodiment of the invention, a centrallycontrolled system is utilized comprising a central computer 12 thatcontacts each remote site and retrieves data directly from RTU 16 atthat site. Site equipment would include a basic RTU 16 configured toreceive a first output signal from level detector 20, produce a secondoutput signal corresponding to the first output signal, and on command,transmit the second output signal to central computer 12. System controland programming are concentrated at central computer 20. Typically,central computer 12 is a standard personal computer and RTUs 16 aresimplified devices which act primarily as data collection devices and,as a result, require minimal programming.

Preferably, an ultrasonic level detector 24 and/or a strain gauge leveldetector 26 are used to measure the contents of storage vessel 15. Forexample, strain gauges 26 can be placed on legs 27 of storage vessel 15to measure the change in length of legs 27 that is caused by the changein quantity of material in storage vessel 15. These devices typicallyproduce a signal in the range of four to twenty milliamps, which isproportional to the material quantity in the vessel. A preferredultrasonic level indicator is available from Kistler-Morse under thetrade name Sonocell. Remote telemetry unit (RTU) 16 receives the four totwenty milliamp analog signals and converts them into correspondingdigital signals which can be processed by central computer 12. RTU 16then places a telephone call, on preset two-hour timed intervals, totransmit the converted signals to central computer 12.

It would be understood by those skilled in the art that a RTU may be astand alone unit comprising well known components for analog/digitalsignal conversion and which may additionally include means for automatictransmission of data to a central computer via modem at predeterminedtime intervals, or, alternatively, may comprise a plurality of discretecomponents such as an analog/digital converter, microprocessor and modemalso for providing the function. It is also contemplated to use a leveldetection device having an integrated analog/digital converter andmicroprocessor which can communicate directly with the central computer.

One RTU that has been found to be particularly useful for use inconnection with the present invention is available from ControlMicrosystems and includes the following components: Model RS-232Communication Processor; Model 5501-20 8-Channel Analog Input Module;Model 5103 Power Supply Module; and Model ACX24 Transformer. Suitablestand alone RTUs include the Bristol Babcock Models RTU 3301 and RTU3305, and the Fisher-Rosemount Model ROC 306 Remote OperationsController.

Central computer 12 receives and stores data transmitted from RTUs 16 ateach storage vessel site. Central computer 12 includes commerciallyavailable software used to monitor inventory levels and generatestatistical data and trend graphs based on the transmitted data. Twosuitable software packages are the Lookout Run-Time and LookoutDevelopment software. Other known software packages include BristolBabcock's ZxMMI graphics software and Intellution's FIX MMI graphicspackage.

Advantageously, the aforementioned system can be used by atransportation carrier to maintain sufficient quantities of rawmaterials at a remote manufacturing site. For example, a manufacturerwho wishes to relieve itself from the day-to-day responsibility ofmonitoring, recording and maintaining sufficient raw material stores cancontract with a transportation carrier to provide this service.

In accordance with the invention, the transportation carrier maintains acentral computer for receiving and processing data from a manufacturingplant. Signals are generated to represent the quantity of materiallocated in from one or more storage vessels 15, e.g., a plurality of drybulk storage silos or similar containment structures located at amanufacturing plant. The signals are automatically transmitted, via RTU16, to central computer 12 at predetermined time intervals. Softwaremeans generate statistical data in the form of tables and graphs basedon the periodic signal inputs. The data include material levels,material usage rates and material usage rate changes, and projectedmaterial usage rates. The data is used to plan and schedule shipment ofadditional material to the plant in order to replenish depleted stores.

A manufacturer may preselect suitable vendors for supplying each rawmaterial. This information is provided to the transportation center atthe time of contracting. When raw material levels fall below apredetermined acceptable level, the transportation carrier places anorder with the appropriate vendor for additional material. Thetransportation carrier then coordinates the material shipment from thevendor to the manufacturing site using its own trucks.

The present invention is susceptible to various modifications. Forexample, and referring to FIG. 2, a sensing device 35 may be used todetect a quantity of material in a storage vessel 15. Sensing device 35may determine a material level or a weight of material in storage vessel15. In some instances, a material level is measured by a mechanicalsystem, i.e., strain gauge level detector 26, or by ultrasonic leveldetector 24, e.g., a Kistler-Morse Sonocell. Material weight is mostoften determined using strain gauge level detector 26.

In operation, sensing device 35 determines a quantity of material 37within storage vessel 15, and transmits a signal, that is representativeof that measured material quantity, to a data collection/display unit38, e.g, a Kistler-Morse Sonologic II system. Data collection/displayunit 38 may be located on or adjacent to storage vessel 15, or at leastwithin the general area or facility at which storage vessel 15 islocated. Data collection/display unit 38 outputs an analog signal thatis proportional to the measured material quantity and transmits thatsignal to an RTU 16. RTU 16 transmits a signal indicating materialquantity to central computer 12 over telephone, radio, or othercommunication means 40. RTU 16 may be either configured to initiate thedata communication or to respond to data requests initiated at centralcomputer 12, or both.

It will be understood that RTU 16 may comprise some combination of powersupplies, input/output modules and controllers, and modems of the typeknown in the art and readily available to those skilled in theelectronics and communications arts. Additionally, RTU 16 may be anindividual unit, or may be incorporated within a sensing device, datacollection/display units, or computers. When central computer 12receives data from a remote site, Human-Machine-Interface (HMI)software, e.g., the Lookout software program offered by NationalInstruments, stores and displays the data. Alarms may be generated basedon defined settings and limits, and central computer 12 may be eitherconfigured to initiate the data communication or to respond to datarequests initiated at central computer 12, or both. Information from theHMI software may also be linked to spreadsheets and database software tosummarize information in tabular and graphical form. Information fromthe HMI software also may be automatically uploaded to the Internet foreasy access.

In another example, and referring to FIG. 3, sensing device 35determines a material quantity within storage vessel 15, and transmits asignal, that is representative of that measured material quantity, to adata collection/display unit 42.

Data collection/display unit 42, outputs a signal indicating materialquantity and transmits that signal to central computer 12. In thisembodiment, functions performed by RTU 16 are physically incorporatedwithin data collection/display unit 42. The signal generated by datacollection/display unit 42 can be transmitted over telephone, radio, orother communication means 40. Also, data collection/display unit 42 maybe either configured to initiate the data communication or to respond todata requests initiated at central computer 12, or both.

In yet a further example, and referring to FIG. 4, sensing device 35determines a material quantity within storage vessel 15, and transmits asignal that is representative of that measured material quantity to anon-site computer system 45. On-site computer system 45 outputs an analogsignal that is proportional to the measured material quantity andtransmits that signal to an RTU 16. RTU 16 transmits a signal indicatingmaterial quantity to central computer 12 over telephone, radio, or othercommunication means 40. In this embodiment, RTU 16 may be configured toeither initiate the data communication or to respond to data requestsinitiated at central computer 12, or both.

In still another example, and referring to FIG. 5, sensing device 35determines a material quantity within storage vessel 16, and transmits asignal that is representative of that measured material quantity to anon-site computer system 45. On-site computer system 45 generates asignal proportional to the measured material quantity, and transmitsthat signal to central computer 12 over telephone, radio, or othercommunication means 40. On-site computer system 45 may be configured toeither initiate the data communication or to respond to data requestsinitiated at central computer 12, or both.

In an additional example, and referring to FIG. 6, sensing device 35determines a material quantity within storage vessel 15, and transmits asignal that is representative of that measured material quantity, to anRTU 16. RTU 16 transmits that a signal representative of a materialquantity to central computer 12 over telephone, radio, or othercommunication means 40. RTU 16 may be configured to either initiate thedata communication or to respond to data requests initiated at centralcomputer 12, or both.

In another example, and referring to FIG. 7, sensing device 35determines a material quantity within storage vessel 15, and transmits asignal that is representative of that measured material quantity, tocentral computer 12 over telephone, radio, or other communication means40. Sensing device may be configured to either initiate the datacommunication or to respond to data requests initiated at centralcomputer 12, or both.

The invention having been disclosed in connection with the foregoingvariations and examples, additional variations will now be apparent topersons skilled in the art. The invention is not intended to be limitedto the variations specifically mentioned, and accordingly referenceshould be made to the appended claims rather than the foregoingdiscussion of preferred examples, to assess the scope of the inventionin which exclusive rights are claimed.

1. An automated inventory management system comprising: a sensor thattransmits a first output signal corresponding to a material quantity; adata collector that receives said first output signal from said sensorand transmits a second output signal that is representative of saidmaterial quantity; a remote telemetry unit that receives said secondoutput signal and transmits a signal indicating material quantity; and acentral computer disposed in data communication with said remotetelemetry unit for receiving said signal indicating material quantitywherein said central computer includes means for storing a plurality ofsignals indicating material quantity received by said central computerover time, means for interpreting a past material usage trend based onsaid plurality of signals indicating material quantity, and means forprojecting a material usage rate based on said plurality of signalsindicating material quantity.
 2. The system of claim 1 wherein at leastone of said first output signal, said second output signal, and saidsignal indicating material quantity are transmitted substantiallycontinuously.
 3. The system of claim 1 wherein at least one of saidfirst output signal, said second output signal, and said signalindicating material quantity is transmitted automatically.
 4. The systemof claim 1 wherein at least one of said means for interpreting a pastmaterial usage trend and said means for projecting a material usage ratecomprises software means.
 5. The system of claim 1 wherein said centralcomputer comprises software means for interfacing with the Internet. 6.The system of claim 1 comprising means for generating an alarmindicating said material quantity is less than a predetermined quantitywherein said alarm is at least one of visual and audible.
 7. The systemof claim 1 wherein said central computer further comprises means fordisplaying at least one of said past material usage trend and saidmaterial usage rate in at least one of tablature and graphical form. 8.An automated inventory management system comprising: a sensor thatproduces a first output signal comprising material quantity data; a datacollector that receives said first output signal from said sensor andproduces a second output signal comprising said material quantity data;a remote telemetry unit that receives said second output signal andautomatically transmits a third output signal comprising said materialquantity data; and a computer that receives said third output signalcomprising material quantity data, wherein said computer comprises meansfor storing said material quantity data, means for analyzing saidmaterial quantity data, and means for projecting a material usage ratebased on said material quantity data.
 9. The system of claim 8comprising a network wherein said material quantity data is transmittedautomatically.
 10. The system of claim 8 comprising a network whereinsaid material quantity data is transmitted substantially continuously.11. The system of claim 8 wherein said computer is at least one of alocal computer with a location substantially proximate to said sensorand a central computer with a location substantially remote from saidsensor.
 12. The system of claim 8 wherein at least one of said means foranalyzing said material quantity data and said means for projecting amaterial usage rate based on said material quantity data comprisessoftware means.
 13. The system of claim 8 wherein said computercomprises software means for transmitting said material quantity data tothe Internet.
 14. The system of claim 8 further comprising means forgenerating an alarm when said material quantity data indicates that amaterial quantity is less than a predetermined quantity wherein saidalarm is at least one of visual and audible.
 15. The system of claim 8wherein said computer comprises means for displaying said material usagerate in at least one of tablature and graphical form.
 16. A system tomaintain a sufficient quantity of material at a remote site comprising:a sensor at a remote site that measures a material quantity and producesa first output signal comprising material quantity data; a datacollector that receives said first output signal from said sensor andproduces, at predetermined time intervals, a second output signalcomprising said material quantity data; a remote telemetry unit thatreceives said second output signal and automatically transmits a thirdoutput signal comprising said material quantity data; a computer thatreceives said third output signal from said remote telemetry unit,wherein said computer comprises means for determining said materialquantity, means for storing said material quantity data, means forprojecting a material usage rate based on said material quantity data,and means for automatically ordering additional materials from apreselected vendor based on said material quantity data.
 17. The systemof claim 16 wherein said computer further comprises means for directinga transport vehicle to deliver additional materials to said remote site.18. The system of claim 16 wherein said computer further comprises meansfor coordinating a shipment of additional materials to said remote sitevia a transport vehicle.
 19. The system of claim 16 wherein saidcomputer is at least one of a local computer with a locationsubstantially proximate to said sensor and a central computer with alocation substantially distant from said sensor.
 20. The system of claim16 wherein said material quantity data corresponds to a quantity of drybulk materials.